Sinoboom AB46RJ Maintenance Manual

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Part No.504023110002

Rev: B

Nov. 2022

Maintenance

Manual

产品说明书

PRODU

C T MAN U AL

AB46RJ/AB1530RJ

0608E (2132E)

G T JZ

0808E (2732E)

G T JZ

0808E (2732E)

G T JZ

0808E (2732E)

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Page 1 Maintenance Part No.504023110002 Rev: B Manual Nov. 2022 产品说明书 PRODU C T MAN U AL AB46RJ/AB1530RJ 0608E (2132E) G T JZ 0808E (2732E) G T JZ 0808E (2732E) G T JZ G T JZ 0808E (2732E)
Page 3 Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your...
Page 4 : No.128, East Jinzhou Avenue, Ningxiang High-tech Industrial Park, Changsha, Hunan, China Zip Code : 410600 Copyright © Hunan Sinoboom Intelligent Equipment Co., Ltd. All Rights Reserved The final interpretation right of this manual belongs to Hunan Sinoboom Intelligent Equipment Co., Ltd.
Page 5 (See Decals/Nameplates Inspection of the Operation Manual for details.) Trade Identification Model Serial No. Imperial Metric From 0402300104 to present AB46RJ AB46RJ AB1530RJ NOTE: • Product model is applied in product nameplate for distinction of products of different main parameters.
Page 6 This Page Intentionally Left Blank...
Page 7 This manual covers the basic parts information of one or more products. Therefore, please use this manual according to your needs. If you find problems in the manual or have suggestions for improve- ment, feel free to share your feedback with Sinoboom, and we will address these issues as soon as possible.
Page 8 This Page Intentionally Left Blank...
Page 9: Table Of Contents
Hydraulic System ..... 3-1 Pins and composite bearing... 4-5 AB46RJ Maintenance Manual © Nov. 2022...
Page 11 Use and Maintenance of Battery. . .6-34 Electrical Symbols ....6-36 Electrical Schematic Diagram ..6-38 7 Control system ....7-1 AB46RJ Maintenance Manual © Nov. 2022...
Page 13: Introduction
The owner or administrator of the machine shall also provide the manufacturer’s maintenance information to the person responsible for maintaining the machine. If you have any questions, contact Hunan Sinoboom In- telligent Equipment Co., Ltd.. AB46RJ Maintenance Manual © Nov. 2022...
Page 15: Safety
In case of any accident involving the machinery of Also, people who have alcohol or drugs in their Hunan Sinoboom Intelligent Equipment Co., Ltd., notify system, or experience excessive fatigue or Hunan Sinoboom Intelligent Equipment Co., Ltd.
Page 16: Electrocution Hazards
Table 1-1 Minimum Safe Distance Voltage Minimum Safe Distance (Phase to Phase, kV) (m/ft) 0-50 3.05 (10) 50-200 4.60 (15) 200-350 6.10 (20) 350 -500 7.62 (25) 500 -750 10.67 (35) 750 -1000 13.725 (45) © Nov. 2022 AB46RJ Maintenance Manual...
Page 17 The battery is vital reduce the stability of the to maintaining the stability of the machine. machine. • When the machine is on rough ground, with gravel or other uneven surfaces, or near holes AB46RJ Maintenance Manual © Nov. 2022...
Page 18: Work Environment Hazards
3. Lower the main boom. • Running speed should not exceed 0.48 km/h (0.3 mph) when the platform rises. • If the machine can be used outdoors, never operate it in strong or gusty wind. Do not lift © Nov. 2022 AB46RJ Maintenance Manual...
Page 19 If the machine is to be used in increase the wind load on the any special workplace or work method other than those machine. specified by Hunan Sinoboom Intelligent Equipment • Do not drive or lift the machine on Co., Ltd., the manufacturer’s approval and guidance slopes, steps or vaulted surfaces should be obtained first.
Page 20: Unsafe Operation Hazards
The battery not only provides power, but also serves as a counterweight. The battery is vital to maintaining the stability of the machine. © Nov. 2022 AB46RJ Maintenance Manual...
Page 21: Fall Hazards
FALL HAZARDS At a minimum, operators must operate and maintain the machine as stated in the operation manual and in the maintenance manual in addition to following more stringent industry regulations and workplace rules. AB46RJ Maintenance Manual © Nov. 2022...
Page 22: Crush Hazards
• Limit the speed of travel according to ground conditions, crowding, gradients, the presence and location of personnel and any © Nov. 2022 AB46RJ Maintenance Manual...
Page 23: Explosion And Fire Hazards
NOTICE To avoid machine damage, follow all operation and Always follow all operation and maintenance maintenance requirements in the Operation Manual requirements in the Operation Manual and the and the Maintenance Manual. Maintenance Manual. AB46RJ Maintenance Manual © Nov. 2022...
Page 24: Battery Hazards
Keep any device that may cause sparks or flames (including cigarettes/smoking materials) away from the battery to prevent explosion. • Do not touch the battery terminals or cable clips with tools that may cause sparks. © Nov. 2022 1-10 AB46RJ Maintenance Manual...
Page 25 • Never store the battery in water or humid atmosphere. • Daily check the battery cable for damage, and replace any damaged parts before operating the machine. AB46RJ Maintenance Manual 1-11 © Nov. 2022...
Page 26: Hydraulic Hazards
OFF position. 7. Turn the key switch at the ground controls to OFF position and remove the key to avoid unauthorized operation of the machine. 8. Turn off the main power switch. © Nov. 2022 1-12 AB46RJ Maintenance Manual...
Page 27 SAFETY NOTICE After using the machine, the main power switch must be disconnected. AB46RJ Maintenance Manual 1-13 © Nov. 2022...
Page 29: Specifications
SPECIFICATIONS PERFORMANCE PARAMETERS Table 2-1 AB46RJ specifications AB46RJ (METRIC) AB1530RJ (IMPERIAL) MEASURE DIMENSION PARAMETERS Max. platform height 46.6 m 152 ft 11 in Max. working height 48.6 m 159 ft 5 in Max. horizontal reach 25.5 m 83 ft 8 in Max horizontal working envelope 26.1 m...
Page 30 Max. allowable RH Stored at -20℃ to 50℃ (-4℉ to 122℉) in a well-ventilated environment with Storage environment 90% relative humidity (20℃ [68℉]), and away from rain, sun, corrosive gases, inflammables and explosives. WEIGHT © Nov. 2022 AB46RJ Maintenance Manual...
Page 31 The loads of persons, accessories, tools and materials are factored into the rated platform capacity. g) The total vibration value of the platform does not exceed 2.5m/s², and the maximum root-mean-square value of the weighted acceleration of the entire machine does not exceed 0.5m/s². AB46RJ Maintenance Manual © Nov. 2022...
Page 32 SPECIFICATIONS AB46RJ (5°) platform reach chart 275 kg (606 lb) 455 kg (1003 lb) © Nov. 2022 AB46RJ Maintenance Manual...
Page 33: Engine Specifications
0.96 gal (US) Outrigger retracting 20～30s Compression 17.5：1 Max drive speed (30m) Ratio 22～26s Firing Order 1-3-4-2 Output 74kW@2200rpm 420Nm (310 ft-lb)） Max.torque @1300–1600rpm Engine Oil Capacity 2.64 gal (UK) 3.17 gal (US) IdleSpeed 1000rpm AB46RJ Maintenance Manual © Nov. 2022...
Page 34: Major Component Weights
• Do not place heavy component from the fully extended position twice. upon instable surface. Articulated boom extending/retracting: With the articulated boom fully raised, fully extend the articulated © Nov. 2022 AB46RJ Maintenance Manual...
Page 35 Main boom lift cylinder 1929 Jib boom lift cylinder Leveling cylinder Slewing mechanism 1232 Engine-Cummis Engine-YUCHAI Fuel tank Outrigger extending cylinder Steer cylinder Outrigger 1510 Tire assembly Drive reducer Motor Power unit Hydraulic rotary coupler AB46RJ Maintenance Manual © Nov. 2022...
Page 36: Power System Specifications
Drive Motor Type Plunger motor Displacement 45 cc/r Function Manifold Boom function valve pressure 24 MPa (3480Psi) Return Filter Return filter bypass pressure 0.02 MPa (2.9Psi) High-pressure Filter High-pressure filter bypass pressure 0.2 MPa (2.9Psi) © Nov. 2022 AB46RJ Maintenance Manual...
Page 37: Hydraulic Hose And Fitting
40 ± 3 Nm (30 ± 3 ft-lb) M16×1.5 75 ± 5 Nm (55 ± 4 ft-lb) 75 ± 5 Nm (55 ± 4 ft-lb) 45 ± 3 Nm (33 ± 4 ft-lb) M18×1.5 AB46RJ Maintenance Manual © Nov. 2022...
Page 38 240 ± 15 Nm (177 ± 11 ft-lb) 450 ± 25 Nm (332 ± 18 ft-lb) G1-1/2A 280 ± 20 Nm (207 ± 15 ft-lb) 540 ± 30 Nm (398 ± 22 ft-lb) © Nov. 2022 2-10 AB46RJ Maintenance Manual...
Page 39 110 ± 8 Nm (81 ± 6 ft-lb) 185 ± 15 Nm (136 ± 11 ft-lb) 1-5/16-12 160 ± 10 Nm (118 ± 7 ft-lb) 280 ± 20 Nm (207 ± 15 ft-lb) AB46RJ Maintenance Manual 2-11 © Nov. 2022...
Page 40: Hydraulic Hose And Fitting Tight
500 Nm (369 ft-lb) 650 Nm(479 ft-lb ) 770 Nm (568 ft-lb) 600 Nm (443 ft-lb) 800 Nm (590 ft-lb) 980 Nm (723 ft-lb) 650 Nm (479 ft-lb) 850 Nm (627 ft-lb) 1050 Nm (774 ft-lb) © Nov. 2022 2-12 AB46RJ Maintenance Manual...
Page 41 200 Nm (148 ft-lb) 9/16-18 13/16" 200 Nm (148 ft-lb) 280 Nm (207 ft-lb) 5/8-18 15/16" 350 Nm (258 ft-lb) 495 Nm (365 ft-lb) 3/4-16 1-1/8" 560 Nm (413 ft-lb) 780 Nm (575 ft-lb) 7/8-14 AB46RJ Maintenance Manual 2-13 © Nov. 2022...
Page 43: System Descriptions
The batteries are charged by the DC generator of the engine. Power- off switches are used to protect the control system. AB46RJ Maintenance Manual © Nov. 2022...
Page 45: Service And Guidelines
Machine positions Stowed position: A qualified Sinoboom equipment mechanic is a person recognized by Sinoboom as one who, by possession of Boom lowers and retracts in place. a recognized degree, certificate and training, has Non-operating position (high drive speed mode...
Page 46: Annual Machine Inspection
Hunan Sinoboom Intelligent Equipment Co., Ltd. recommends this task be performed by a factory-trained service technician, a person recognized by Sinoboom as one who, by possession of a recognized degree, certificate, training, has successfully demonstrated the ability and proficiency to service, repair and maintain the subject Sinoboom product model.
Page 47: Storage
Never attempt to move heavy parts without the aid of a this manual. mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided. AB46RJ Maintenance Manual © Nov. 2022...
Page 48: Cleanliness
• The static and dynamic load tests of the machine suggest a compliance with the relevant standard. © Nov. 2022 AB46RJ Maintenance Manual...
Page 49: Pressure-Fit Parts
2. Unless specific torque requirements are given • Excessive sloppiness in joints. within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in • Noise originating from the joint during operation. AB46RJ Maintenance Manual © Nov. 2022...
Page 50: Application Of Insulating Silicone Grease To Electrical Connections
1. Prior to the machine assembling, apply silicone grease around the male pins and female pins inside the connectors to prevent oxidization. An injector may be used for the convenience of operation. © Nov. 2022 AB46RJ Maintenance Manual...
Page 51: Maintenance
& counterbalance valve on the cylinder. inspection report. • Immediately remove a damaged or malfunctioning machine from service, mark and stop using it. AB46RJ Maintenance Manual © Nov. 2022...
Page 52: Conducting A Pre-Delivery Inspection
Every half a year or every 500 involved. Use the table to help you adhere to a routine A+B+C hours maintenance schedule. Every year or every 1000 hours A+B+C+D © Nov. 2022 AB46RJ Maintenance Manual...
Page 53: Completing A Repair & Inspection
A-8 Inspect Engine Oil Level A-9 Inspect Coolant Level A-10 Inspect Engine Belt A-11 Inspect Fuel Strainer (Oil-Water Separator) A-12 Inspect Cooling Fan A-13 Inspect Engine Intake System A-14 Functional Tests A-15 Perform Maintenance after 30 Days AB46RJ Maintenance Manual © Nov. 2022...
Page 54 B-13 Inspect Slewing Bearing Bolts B-14 Lubricate Slewing Bearing B-15 Inspect Platform Oscillating Cylinder Fasteners B-16 Test Cylinder Drift B-17 Test Drive Speed B-18 Inspect Electrical Wiring B-19 Inspect Battery B-20 Inspect Tilt Protection © Nov. 2022 AB46RJ Maintenance Manual...
Page 55 D-2 Replace Slewing Reducer Gear Oil D-3 Replace Hydraulic Oil D-4 Replace Hydraulic Tank Suction Filter D-5 Replace Coolant and Coolant Hoses D-6 Replace Fuel Hoses D-7 Inspect Boom Wear Pads User Inspector Signature Inspection Date AB46RJ Maintenance Manual © Nov. 2022...
Page 56: Major Modification And Repair Record
“Good” condition before company. continuing to use the machine. Table 5-4 Major Modification and Repair Record Model Serial No. Machine Repair- Repairman’s Status Problem Description Modification/Repair Item Date Company and Signature Position ter Change © Nov. 2022 AB46RJ Maintenance Manual...
Page 57: Checklist Aprocedures
Alarms and lighting (if equipped) each use. • Platform（including rails, floor plate, safety lock, Note: If the manuals need to be replaced, please brackets and entry door） contact Hunan Sinoboom Intelligent Equipment Co., Ltd.. • Personal protection equipment • Emergency control equipment A-2 Inspect All Decals •...
Page 58: Inspect Hydraulic Leakage
Extremely cold region Special programmes less than -30°C (-22°F) need to be identified. NOTICE Different hydraulic oils can be added according to customer requirements upon factory delivery, but cannot be mixed. Figure 5-2 © Nov. 2022 AB46RJ Maintenance Manual...
Page 59: Inspect Fuel Leakage
• Ensure that a conforming fire ambient temperature. extinguisher is readily accessible when performing this inspection procedure. Inspect for diesel spills, drippings or residues in the following areas： • Fuel tank, piping and fittings AB46RJ Maintenance Manual © Nov. 2022...
Page 60: Inspect Engine Oil Level
CH-4 with viscosity grade of 15W-40. the cover to release the pressure. Table 5-7 VISCOSITY RECOMMENDED AMBIENT TEMP 0W-30 -35℃～0℃ 5W-40 -25℃～30℃ NOTICE 15W-40 -15℃～40℃ Turn off the engine before inspection. 20W-50 0℃～50℃ Cummis © Nov. 2022 5-10 AB46RJ Maintenance Manual...
Page 61 -18℃ ready-mix coolant or the coolant with ethylene glycol anti- freeze (ethylene and propene) and water mixed in ratio. The water quality must meet the requirements as listed in the table below. AB46RJ Maintenance Manual 5-11 © Nov. 2022...
Page 62: Inspect Engine Belt
Glazing or hardening • Improper tensioning (press at the middle position of the mostly extended belt between the pulleys to check the tensioning condition, the press-down of belt should not exceed 13mm [0.5 in.].) © Nov. 2022 5-12 AB46RJ Maintenance Manual...
Page 63: Water Separator
4. Tighten the valve plug. or unusual noise. 5. Clean up the spilled fuel. 6. Start the engine from the ground controller and inspect the fuel strainer (fuel-oil separator) for leakage. AB46RJ Maintenance Manual 5-13 © Nov. 2022...
Page 64 18. Engine preheat switch 2. ON position 10. Main boom telescope switch (if equipped) 3. OFF position 11. Turntable rotate switch 19. Ground/Platform select switch 20. Emergency stop button 4. Horn 12. Jib rotate switch © Nov. 2022 5-14 AB46RJ Maintenance Manual...
Page 65 3. OFF position 11. Turntable rotate switch 19. Ground/Platform select switch 20. Emergency stop button 4. Horn 12. Jib rotate switch 5. Key switch 13. Jib up/down switch 21. Platform control position AB46RJ Maintenance Manual 5-15 © Nov. 2022...
Page 66 31. Platform height 7. Machine info 19. Chassis tilt alarm 32. Main boom angle above 8. Turntable info 20. Platform tilt alarm horizontal 21. Heavy load indicator 9. Platform info 33. Boom horizontal reach © Nov. 2022 5-16 AB46RJ Maintenance Manual...
Page 67 9. Low fuel level indicator light equipped) proportional control 38. Main boom auto-control mode 10. System distress indicator light 24. Speed adjusting button switch 11. Chassis tilt indicator light 25. Machine stowed switch 39. X/Y drive switch AB46RJ Maintenance Manual 5-17 © Nov. 2022...
Page 68: Perform Maintenance After
4. Loosen the filter end cap and remove the filter NOTICE element. 5. Apply a thin coat of oil film over the new gasket of Shut off the engine before inspection. return filter. 1. Open the right side cover of the turntable. © Nov. 2022 5-18 AB46RJ Maintenance Manual...
Page 69: Fasteners
A dirty or blocked strainer hydraulic oil or filter of the new machine. may cause the machine to work improperly. and continued operation may result in component damage. AB46RJ Maintenance Manual 5-19 © Nov. 2022...
Page 70: Water Separator) Element
NOTICE Shut off the machine before inspection. Figure 5-14 Cummins QSF3.8t3TC99 Fuel- water separator 1. Remove the air filter of hydraulic tank. Figure 5-15 Yuchai YCF36100-T480 fuel strainer © Nov. 2022 5-20 AB46RJ Maintenance Manual...
Page 71: Replace High-Pressure Filter
Bodily contact with hot hydraulic oil may result in severe burn. Inspecting the engine air filter is vital to proper engine operation. Failure to perform this inspection procedure will result in engine malfunction and component damage. AB46RJ Maintenance Manual 5-21 © Nov. 2022...
Page 72: Sensors
Regularly inspecting length and angle sensors is vital to NOTICE safe machine operation. If the sensors can’t function properly, it will pose dangers to machine operation. Shut off the engine before inspection. Inspecting length sensor © Nov. 2022 5-22 AB46RJ Maintenance Manual...
Page 73: Inspect Drive Reducer Oil
8. Perform the inspection procedure to all drive Loctite 272 to the new bolts and torque to specification. reducers of the machine. After the bolts are replaced and torqued, re-inspect the bolts for tightness. AB46RJ Maintenance Manual 5-23 © Nov. 2022...
Page 74 4. Ensure the feeler gauge won’t go through the outside of bolt head to the bolt shank. 5. Rotate the turntable to inspect all the bolts. Inspecting the connecting bolts between turntable and slewing bearing © Nov. 2022 5-24 AB46RJ Maintenance Manual...
Page 75: Lubricate Slewing Bearing
0.04mm feeler gauge in between the bolt and washer. 4. Ensure the feeler gauge won’t go through the outside of bolt head to the bolt shank. 5. Lower the main boom to be horizontal and fully extend it. AB46RJ Maintenance Manual 5-25 © Nov. 2022...
Page 76: Test Cylinder Drift
(high drive speed Cylinder Bore Maximum Allowable Drift in 4.5 km/h (2.8 mph) unrestricted)-outrigger Diameter 10 Minutes retracted (mm/in) (mm/in) Non-operating 63/2.48 0.96/0.037 (high drive speed 1 km/h (0.62 mph) restricted) 80/3.15 0.63/0.025 100/3.94 0.39/0.015 © Nov. 2022 5-26 AB46RJ Maintenance Manual...
Page 77: Inspect Electrical Wiring
3. Ensure the battery cable connections are not corroded. Note: Adding a terminal protector and anti- corrosion sealant will prevent the terminals and cables from corrosion. The instructions below are applied only for batteries requiring maintenance： AB46RJ Maintenance Manual 5-27 © Nov. 2022...
Page 78: Inspect Tilt Protection
7. With the machine in non-operating position, drive 2. Pull out the emergency stop buttons on both the the machine down the slope. ground and platform controllers to ON position. © Nov. 2022 5-28 AB46RJ Maintenance Manual...
Page 79: Test Braking Distance
1. Open the left side cover of turntable and locate the fuel filter. 2. Disconnect and plug the hose between fuel tank and fuel filter. AB46RJ Maintenance Manual 5-29 © Nov. 2022...
Page 80: Inspect Boom Extend/Retract
The cables and pulleys should be replaced together, drain plug i.e., if the cable is replaced, the matching pulley should also be replaced. Note:Replace the wire ropes if any of the following indicators are present: 1. Rusted or corroded ropes; © Nov. 2022 5-30 AB46RJ Maintenance Manual...
Page 81: Replace Engine Oil Filter
6. Mount the new filter. is replaced. 7. For the engine oil level inspection procedure, please reference A-8 Inspect Engine Oil Level, page 5-10. 8. Inspect the engine oil filter element to make sure no leakage occurs. AB46RJ Maintenance Manual 5-31 © Nov. 2022...
Page 82: Hydraulic Tank
The time of the override operation and the actual weight on the platform are recorded on the display. © Nov. 2022 5-32 AB46RJ Maintenance Manual...
Page 83: Checklist Dprocedures
1,000 hours. Particularly harsh working condition requires oil change to be performed more frequently. BURN HAZARD Before servicing the hydraulic system, allow the hydraulic oil to cool down to room temperature. AB46RJ Maintenance Manual 5-33 © Nov. 2022...
Page 84: Replace Hydraulic Tank
Extremely dirty condition requires the oil changes to be performed more 2. Disconnect the coolant return hose, and drain the frequently. coolant inside the return hose into a suitable vessel. © Nov. 2022 5-34 AB46RJ Maintenance Manual...
Page 85: Replace Fuel Hoses
Diesel is an inflammable material. This procedure must be performed outdoors in well-vented area and far away from flames. • Ensure that a conforming fire extinguisher is readily accessible when performing this inspection procedure. AB46RJ Maintenance Manual 5-35 © Nov. 2022...
Page 86 The wear pad thickness specifications are listed in the table 16mm (0.63in) below. 18mm (0.71in) Table 5-17 28mm (1.10in) Thickness Specifications 30mm (1.18in) 22mm (0.87in) 20mm (0.79in) 16mm (0.63in) © Nov. 2022 5-36 AB46RJ Maintenance Manual...
Page 87 3mm (0.118in.), the wear pad assembly should be timely replaced. NOTICE The wear pad disassembled from the boom should never be reused. Be sure to replace it with a new wear pad asssembly. AB46RJ Maintenance Manual 5-37 © Nov. 2022...
Page 89: Repair Procedures
The retracting wire rope is installed outside the boom so that the failures with retracting AB46RJ Maintenance Manual © Nov. 2022...
Page 90: Platform Controller
3. Use a suitable device to support the platform swing motor bracket 3#. 4. Remove the retaining bolts 1# and pivot pin 2#, and then remove the swing motor bracket 3#. 5. Use a suitable device to support the platform swing motor. © Nov. 2022 AB46RJ Maintenance Manual...
Page 91: Jib Boom Assembly
1# out with brass drift and wooden within 150°. hammer. 4. Remove the bolt at the pivot pin 2# connecting the second telescopic boom of main boom, and drive the pivot pin 2# out with brass drift and wooden hammer. AB46RJ Maintenance Manual © Nov. 2022...
Page 92: Platform Leveling Cylinder
MOVING OBJECT HAZARD Wear eye protection when tapping the brass drift with a wooden hammer. NOTICE When removing the cylinder, special care should be taken to avoid the fall of the cylinder and component damage. © Nov. 2022 AB46RJ Maintenance Manual...
Page 93: Cable Track Assembly
4. Using a suitable lifting device, fully support the 1. Position the main boom to be horizontal and extend cable track of the articulated boom along the entire it 1.5-1.8m (5ft-6ft). length. 2. Remove the lock nuts from the wire rope retainer. AB46RJ Maintenance Manual © Nov. 2022...
Page 94: Main Boom Assembly
7. Using a wrench, torque alternately the adjusting hammer. nuts of the both extending wire ropes to 112 Nm (82.68 ft-lb). © Nov. 2022 AB46RJ Maintenance Manual...
Page 95 4t), secure the lifting straps to the lower end of the main boom. Figure 6-13 9. Remove the bolts and nuts at the pin #3 connecting the main boom with the articulated boom. AB46RJ Maintenance Manual © Nov. 2022...
Page 96: Chassis And Turntable Components
Replacing tires and rims coming loose. Use a torque wrench to tighten the fasteners. If Hunan Sinoboom Intelligent Equipment Co., Ltd. you do not have a torque wrench, recommends the replacement tires be of the same size, tighten the fasteners with a socket ply rating and brand as the original tires.
Page 97: Reducer And Drive Motor
Reducer and Drive Motor motor mounting grooves are aligned with the reducer mounting bolts. 7. Apply the threadlocker Loctite 272 to the bolts and torque the bolts after pre-tightening. 8. Attach the hydraulic hoses. Figure 6-15 AB46RJ Maintenance Manual © Nov. 2022...
Page 98: Turntable Slewing Mechanism
Loctite 272 to the bolt, and install the bolts one by one. 4. Tighten the bolts in the sequence as shown in the figure below. © Nov. 2022 6-10 AB46RJ Maintenance Manual...
Page 99: Engine
Fig 6-17 , page 6-11, and tighten the retaining bolts in the sequence as indicated. 12. Refer to Table 6-3 , page 6-11, and tighten the bolts per the recommended torques and sequence. AB46RJ Maintenance Manual 6-11 © Nov. 2022...
Page 100: Hydraulic System
REPAIR PROCEDURES HYDRAULIC SYSTEM Layout of Hydraulic Elements © Nov. 2022 6-12 AB46RJ Maintenance Manual...
Page 101 10. Main valve control valve 17. Articulated boom lifting/lowering counterbalance valve 4.Steer control valve 11. Cycloid motor 18. Articulated boom telescoping counterbalance valve 5. Brake/2–speed control valve 12. Oil return valve 19. Leveling counterbalance valve AB46RJ Maintenance Manual 6-13 © Nov. 2022...
Page 102 REPAIR PROCEDURES 6. High-pressure filter 13. Hydraulic tank 20. Platform control valve group 7. Open-type variable displacement 14. Main boom telescoping pump counterbalance valve © Nov. 2022 6-14 AB46RJ Maintenance Manual...
Page 103: Function Valves
REPAIR PROCEDURES Function Valves 17-1 16-2 12-5 12-1 17-2 17-3 17-4 12-4 19-3 12-6 12-7 19-2 12-3 19-1 12-2 Figure 6-20 Main valve control valves AB46RJ Maintenance Manual 6-15 © Nov. 2022...
Page 104 Keep fluid flowing in one way Check valve 85～95Nm (63～70ft-lb) Keep fluid flowing in one way Check valve 30Nm (22ft-lb) Cut off oil line during emergency operation Solenoid valve 30Nm (22ft-lb) Warm up hydraulic oil Solenoid valve © Nov. 2022 6-16 AB46RJ Maintenance Manual...
Page 105 Figure 6-21 Articulated boom lifting/lowering counterbalance valve Table 6-6 Articulated boom lifting/lowering counterbalance valve NAME TORQUE FUNCTION Control the speed of articulated boom lifting/ Proportional 45～50Nm (33～37ft-lb) lowering solenoid valve Counterbalance 40～48Nm (30～35ft-lb) Maintain load valve AB46RJ Maintenance Manual 6-17 © Nov. 2022...
Page 106 Control the speed of articulated boom extending/ Proportional 45～50Nm (33～37ft-lb) retracting solenoid valve Counterbalance 60～70Nm (44～52ft-lb) Maintain load valve Counterbalance 60～70Nm (111～118ft-lb) Maintain load valve 5Nm (9ft-lb) Shuttle valve Switch oil lines Damper 5Nm (9ft-lb) © Nov. 2022 6-18 AB46RJ Maintenance Manual...
Page 107 45～50Nm (33～37ft-lb) Control the speed of main boom lifting/lowering solenoid valve Counterbalance 40～48Nm (30～35ft-lb) Maintain load valve 5Nm (9ft-lb) Shuttle valve Switch oil lines Counterbalance 40～48Nm (30～35ft-lb) Maintain load valve Damper 5Nm (9ft-lb) AB46RJ Maintenance Manual 6-19 © Nov. 2022...
Page 108 Keep fluid flowing in one way Check valve Hydraulic 41～47Nm (30～35ft-lb) Keep fluid flowing in one way controlled valve Counterbalance 41～47Nm (30～35ft-lb) Maintain load valve Counterbalance 40～48Nm (30～35ft-lb) Maintain load valve Damper 5Nm (9ft-lb) Damper 5Nm (9ft-lb) © Nov. 2022 6-20 AB46RJ Maintenance Manual...
Page 109 Control the pressure of jib lifting/lowering 6–4 Relief valve Proportional 25～27Nm (18～20ft-lb) Control the speed of jib lifting/lowering 7–1 solenoid valve Proportional 25～27Nm (18～20ft-lb) Control the speed of jib rotation 7–2 solenoid valve AB46RJ Maintenance Manual 6-21 © Nov. 2022...
Page 110 Figure 6-26 Drive control valve Table 6-11 Drive control valve NAME TORQUE FUNCTION Dividing- 99～104Nm (73～77ft-lb) 1–1 Control flow combining valve Dividing- 99～104Nm (73～77ft-lb) 1–2 Control flow combining valve Damper 5Nm (4ft-lb) 2–1 Damper 5Nm (4ft-lb) 2–2 © Nov. 2022 6-22 AB46RJ Maintenance Manual...
Page 111 Switch oil lines 12～15Nm (9～11ft-lb) 7–3 Shuttle valve Switch oil lines Damper 5Nm (4ft-lb) 8–1 Damper 5Nm (4ft-lb) 8–2 Damper 5Nm (4ft-lb) 8–3 3-5 3-6 1-2 1-1 3-3 3-4 Figure 6-27 Steer control valve AB46RJ Maintenance Manual 6-23 © Nov. 2022...
Page 112 Relief valve 40～45Nm (30～33ft-lb) Control the pressure of front axle extending cylinder 3–6 Relief valve Damper 5Nm (4ft-lb) Dividing- 65–71Nm (48～52ft-lb) Control the flow of oil line combining valve 4-1 4-2 3 8 © Nov. 2022 6-24 AB46RJ Maintenance Manual...
Page 113 10—way Y-type 15Nm (11ft-lb) Control the direction of main boom lifting/lowering 5–2 gate valve Control the main boom and articulated boom in 40～45Nm (30～33ft-lb) Solenoid valve case of emergency Damper 5Nm (4ft-lb) Piston AB46RJ Maintenance Manual 6-25 © Nov. 2022...
Page 114 Table 6-14 Brake/2-speed control valve TORQUE NAME FUNCTION Pressure 33.9Nm (25ft-lb) Control brake/2-speed pressure reducing valve Damper 27.1Nm (20ft-lb) 3–1 Solenoid valve Control brake direction 27.1Nm (20ft-lb) Control 2-speed direction 3–2 Solenoid valve Damper Damper Damper © Nov. 2022 6-26 AB46RJ Maintenance Manual...
Page 115: Hydraulic Symbols
32.0000 28.5682 17.4787 46.7096 Check valve 28.5682 46.7096 Emergency power 28.5682 16.0000 34.4087 46.7096 34.4087 32.0000 Hydraulic motor 棕兰 32.0000 黑 16.0000 28.5682 16.0000 Overflow valve 17.4787 46.7096 34.4087 32.0000 28.5682 16.0000 AB46RJ Maintenance Manual 6-27 © Nov. 2022...
Page 116: Hydraulic Schematic Diagram
Right Rear Steering Two speed/brake Manifold BR AR MAL MA3 MA3 MAL AL BL DT20 DT21 Axle Control Manifold Axle Control Manifold Right Rear left Rear DT24 DT25 Figure 6-30 AB46RJ hydraulic schematic diagram © Nov. 2022 6-28 AB46RJ Maintenance Manual...
Page 117: Electrical System
7-second limit alarm second limit alarm Check whether the obstacle detection switch Obstacle detection Obstacle detection alarm functions properly alarm Drive controller Drive controller error alarm Check the associated error of drive controller error alarm AB46RJ Maintenance Manual 6-29 © Nov. 2022...
Page 118 Check the wiring of platform swing right solenoid solenoid valve fault valve fault valve Platform leveling up Platform leveling up solenoid Check the wiring of platform leveling up solenoid solenoid valve fault valve fault valve © Nov. 2022 6-30 AB46RJ Maintenance Manual...
Page 119 Check whether the main boom relative angle angle sensor sensor comparison error sensor is correctly installed comparison error Main boom relative Main boom relative angle Check the wiring of main boom relative angle angle sensor fault sensor fault sensor AB46RJ Maintenance Manual 6-31 © Nov. 2022...
Page 120 (highest-level severity) Electrical circuit #1 of coolant level High-voltage short circuit sensor Electrical circuit #1 of coolant level Low-voltage short circuit sensor Data valid but lower than normal Coolant level (medium-level severity) © Nov. 2022 6-32 AB46RJ Maintenance Manual...
Page 121 SAE J1939 accelerator pedal sensor Update error 3326 system Update error 3613 Coolant level sensor Engine coolant level sensor 3614 Network data error Smart control device or component Engine control calibration module 3697 damaged AB46RJ Maintenance Manual 6-33 © Nov. 2022...
Page 122: Use And Maintenance Of Battery
(- continued use after battery level less than 10%) or battery out of charge for a long time (not timely charged for 3 days or longer when the battery level less than 10%). © Nov. 2022 6-34 AB46RJ Maintenance Manual...
Page 123 The self-discharge process will • Recharge the battery before use after removing it accelerate in warmer temperatures. If storing the from storage. battery in hot temperatures or during hot weather, AB46RJ Maintenance Manual 6-35 © Nov. 2022...
Page 124: Electrical Symbols
10%). θ Electrical Symbols Table 6-19 Symbol Description Level switch Buzzer Oil temperature θ switch θ θ θ Valve Delay relay θ Two lines connected Power-off switch θ Motor Relay 28.5682 46.7096 © Nov. 2022 6-36 AB46RJ Maintenance Manual...
Page 125 Description Symbol Description Key switch Warning lamp Preheating wire Valve Two lines non- connected 兰棕 Proximity switch/ 黑 Pressure sensor 28.5682 46.7096 28.5682 兰棕黑 Fuel level sensor 46.8000 Horn 28.5682 AB46RJ Maintenance Manual 6-37 © Nov. 2022...
Page 126: Electrical Schematic Diagram
XC2:43 XJ2-5 PWM_OUT_46 XJ1-13/14 XJ1-3/4 PWM/OUT_45 XJ1-17/18 XJ1-1/2 OUT_24 XJ1-15/16 L202/203 XJ1-19/20 IN_48 OUT_23 2/07 XJ1-11/12 IN_49 OUT_26 XJ1-9/10 2/08 XJ1-7/8 IN_50 OUT_25 2/09 XJ1-5/6 L201 Figure 6-31 Electrical schematic diagram of turntable(Cummis) © Nov. 2022 6-38 AB46RJ Maintenance Manual...
Page 127 XJ2-5 PWM_OUT_46 XJ1-13/14 XJ1-3/4 PWM/OUT_45 XJ1-17/18 XJ1-1/2 OUT_24 XJ1-15/16 L202/203 XJ1-19/20 IN_48 OUT_23 2/07 XJ1-11/12 IN_49 OUT_26 XJ1-9/10 2/08 XJ1-7/8 IN_50 OUT_25 2/09 XJ1-5/6 L201 120Ω Figure 6-32 Electrical schematic diagram of turntable(YUCHAI) AB46RJ Maintenance Manual 6-39 © Nov. 2022...
Page 128 SQ107 V(C)_IN_59 PWM_OUT_39 V(C)_IN_60 PWM_OUT_40 V(C)_IN_56 OUT_24 IN_47 H103 IN_48 L105 L106 OUT_23 H104 欧 IN_49 OUT_26 H105 IN_50 OUT_25 H106 L107/108 H100 HG100 S116 SB100 Figure 6-33 Electrical schematic diagram of platform © Nov. 2022 6-40 AB46RJ Maintenance Manual...
Page 129 PWM_OUT_41 V_IN_34 Y32b PWM_OUT_42 V(C)_IN_58 Y32a PWM_OUT_37 V(C)_IN_53 Y35b PWM_OUT_38 V(C)_IN_59 Y35a PWM_OUT_39 V(C)_IN_60 Y36b PWM_OUT_40 V(C)_IN_56 Y36a IN_47 OUT_24 IN_48 OUT_23 IN_49 OUT_26 IN_50 OUT_25 Figure 6-34 Electrical schematic diagram of chassis AB46RJ Maintenance Manual 6-41 © Nov. 2022...
Page 130 Third Cylinder (1.5) Crankshaft Sensor （ Magnetoelectric 、 Concave teeth ） (1.5) Second Cylinder Camshaft Sensor （ Magnetoelectric 、 Convex teeth ） Exhaust Pres Sensor Figure 6-35 Electrical schematic of engine-Yuchai China Tier 4 © Nov. 2022 6-42 AB46RJ Maintenance Manual...
Page 131: Control System
Therefore, personnel who qualified personnel who have been professionally have not been professionally trained and authorized trained and authorized by Sinoboom, otherwise the by Sinoboom cannot disassemble their housings, consequences will be at your own risk. otherwise moisture and dust will enter the internal mechanism and normal operation will not be guaranteed.
Page 132 Proportional Valve EAT Info Engine Info Engine Fault Diagnoses Turntable Info Turntable Panel Info Platform Panel Info-Input Platform Panel Info-Output Platform Info Alarm Info Alarm Info Fault Info Figure 7-1 Display interface navigation diagram © Nov. 2022 AB46RJ Maintenance Manual...
Page 133: Main Interface After Booting
Turn the ground/platform select switch on the ground controller to the ground control position, pull out the Figure 7-2 Main interface after booting DESCRIPTION OF ICON FUNCTION Table 7-1 Description Description Icon Icon Configuration Left/Right arrow key Increase key Turntable information AB46RJ Maintenance Manual © Nov. 2022...
Page 134: Language Setting
/Press to directly return to the previous menu Up/Down arrow key LANGUAGE SETTING Figure 7-3 CONFIGURATION interface 2. Select Language through , and press 1. Press on the main interface to enter to enter LANGUAGE interface. CONFIGURATION interface. © Nov. 2022 AB46RJ Maintenance Manual...
Page 135: Test-Run Information
3s to complete the calibration (the icon before the selected option is switched from , indicating calibration succeeded, and the corresponding actual value will be changed). AB46RJ Maintenance Manual © Nov. 2022...
Page 136: Weight Calibration
7. If re-calibration is required, press to return to the TEST-RUN INFO interface, then re-enter the WEIGHT CALIBRATION interface, and repeat the previous step. © Nov. 2022 AB46RJ Maintenance Manual...
Page 137: Advanced Setting
CONTROL SYSTEM ADVANCED SETTING Personnel who have not been professionally trained and authorized by Sinoboom are not allowed to modify the advanced setting (including sensor configuration, turntable enable, standardization, proportional configuration, parameter restore/save and reserved setting); otherwise they will be responsible for the consequences.
Page 138: Standardization
KCS standard ( ) will be displayed in the upper right corner of the main interface. • In D/B mode, driving function and boom actions can be performed at the same time. © Nov. 2022 AB46RJ Maintenance Manual...
Page 139: Proportional Configuration
• Minimum current: refers to the starting current of actions, which affects the starting and inching performance of actions. The minimum current should be set to a value that allow the action to just AB46RJ Maintenance Manual © Nov. 2022...
Page 140 TB Lift Up Inspect (Up) Condition of fully raising: up limit switch is triggered or the articulated boom is positioned at an angle bigger than the set value. © Nov. 2022 7-10 AB46RJ Maintenance Manual...
Page 141: Parameter Restore/Save
Notes: All parameters can be adjusted within 0~100. Parameter restore/save 1. On the ADVANCED SETTING interface, select Parameter Restore/Save through , and press to enter PARAMETER RESTORE/SAVE interface. Figure 7-19 PARAMETER RESTORE/SAVE interface AB46RJ Maintenance Manual 7-11 © Nov. 2022...
Page 142: System Information
• The configuration of sensors is subject to the actual machine configuration. Figure 7-20 SYSTEM INFO interface Figure 7-22 SENSOR INFO 1 © Nov. 2022 7-12 AB46RJ Maintenance Manual...
Page 143: Digital Input Information
Figure 7-26 OUTPUT INFO 1 interface the machine meets the requirements. • The configuration of switches is subject to the actual machine configuration. AB46RJ Maintenance Manual 7-13 © Nov. 2022...
Page 144: Proportional Information
EAT INFO interface, and the status indicator light will be on. At this time, it is necessary to contact the engine manufacturer for EAT. Figure 7-29 ENGINE INFO interface © Nov. 2022 7-14 AB46RJ Maintenance Manual...
Page 145 Standstill regeneration is requested indicator light Standstill regeneration is requested, but Fast since the driver has ignored the request for a flashi- long time, the standstill regeneration can only be completed through the DEUTZ diagnostic tool. AB46RJ Maintenance Manual 7-15 © Nov. 2022...
Page 146 Regeneration function is being executed NCD is not working NCD indicator light (- Solid Yanmar only) NCD is working Regeneration prohibiting Conditions prohibiting active regeneration do indicator light (Yuchai only) not exist © Nov. 2022 7-16 AB46RJ Maintenance Manual...
Page 147: Turntable Panel Information
• The configuration of switches on the turntable panel is subject to the actual machine configuration. AB46RJ Maintenance Manual 7-17 © Nov. 2022...
Page 148: Alarm Information
Figure 7-40 FAULT INFO interface 1 Figure 7-38 JOYSTICK INFO interface 3. Press successively to return to the main interface, and power off the machine as required. © Nov. 2022 7-18 AB46RJ Maintenance Manual...
Page 149 BMS Fault Code Description for Lithium Battery section in the Maintenance Manual (if the machine is equipped with any lithium battery). 5. Press successively to return to the main interface, and power off the machine as required. AB46RJ Maintenance Manual 7-19 © Nov. 2022...
Page 151: Appendix 1: Prepare The Work Record Before Delivery
2. Use the table to record the results. After each section is complete, mark the appropriate box. 3. Record the inspection results. If any inspection result is “NO”, the machine must be stopped, and then re- inspected after repair is completed, and the box marked “REPAIRED” shall be checked. AB46RJ Maintenance Manual © Nov. 2022...
Page 153: Appendix 2: Repair & Inspection Report
A-13 Inspect Engine Intake System A-14 Functional Tests A-15 Perform Maintenance after 30 Days Checklist B Procedures YES/Machine is REPAIRED/ NO/Machine Has Machine Has Problem Items Damage or Good Condition Been Description Malfunction Repaired AB46RJ Maintenance Manual © Nov. 2022...
Page 154 B-15 Inspect Platform Oscillating Cylinder Fasteners B-16 Test Cylinder Drift B-17 Test Drive Speed B-18 Inspect Electrical Wiring B-19 Inspect Battery B-20 Inspect Tilt Protection B-21 Inspect Emergency Lowering B-22 Test Braking Distance Checklist C Procedures © Nov. 2022 AB46RJ Maintenance Manual...
Page 155 Reducer Gear Oil D-3 Replace Hydraulic Oil D-4 Replace Hydraulic Tank Suction Filter D-5 Replace Coolant and Coolant Hoses D-6 Replace Fuel Hoses D-7 Inspect Boom Wear Pads User Inspector Signature Inspection Date Inspector Title AB46RJ Maintenance Manual © Nov. 2022...
Page 156 4. If any item is marked as “NO” based on the inspection result, the machine must be stopped and re-inspected after repair is completed, and the box “REPAIRED” should be checked. Select appropriate inspection procedure based on the inspection type. © Nov. 2022 AB46RJ Maintenance Manual...
Page 157: Appendix 3: Major Modification And Repair Record
Modification/Repair” in the form will be “Good” and the machine can be used. If either inspection result is “NO”, the machine must be re-inspected after the repair is completed until the machine is in “Good” condition before continuing to use the machine. AB46RJ Maintenance Manual © Nov. 2022...
Page 158 Solution s Alw ays For B et t er A ccess Solution s Always for Better Access Solutions AS/N ZS Hunan Sinoboom Intelligent Equipment Co., Ltd. 长沙市宁乡高新技术产业园区金洲大道东 128 号 No.128, East Jinzhou Avenue, Ningxiang High-tech Industrial Park, Changsha, Hunan, China 市宁乡高新技术产业园区金洲大道东...

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